Apparatus, system and method of manufacture thereof for insulated structural panels comprising a combination of structural metal channels and rigid foam insulation

ABSTRACT

A insulated structural panel is formed with a rigid foam core, a plurality of vertical hat channels on either face of the rigid foam core, and horizontal top and bottom L-channels on either face of the rigid foam core. The plurality of vertical hat channels on opposing faces of the rigid foam core are attached together so as to compress the rigid foam core, thus adding structural strength to the insulated structural panel.

RELATED PATENT APPLICATION

This application claims priority to commonly owned U.S. Provisional Patent Application Ser. No. 60/630,506; filed Nov. 23, 2004; entitled “Apparatus, System and Method of Manufacture Thereof for Insulated structural Panels Comprising a Combination of Structural Metal Channels and Rigid Foam Insulation,” by Ronnie Onken; which is hereby incorporated by reference herein for all purposes.

TECHNICAL FIELD

The present disclosure relates to insulated structural panels used in building construction, more particularly, insulated structural panels comprising a combination of structural metal channels and rigid foam insulation.

BACKGROUND

Building construction for houses and low rise commercial building have been done with dimensional lumber, e.g., 2× wood studs, bricks, mortar, plywood, stucco, etc. This is referred to in the building industry as “sticks and bricks” construction and is very labor intensive and time consuming for construction of a building. More recently, prefabricated panels made of two sheets of plywood or oriented strand board (OSB) with rigid foam insulation therebetween have been used to construct wall, floors and/or roofs of building. These prefabricated panels, called “structural insulated panels” (SIP) may be fabricated at a manufacturing plant and shipped to a jobsite for rapid erection of a building. The SIPs are stronger and have better insulation properties then a framed dimensional lumber building. Completion of the outer shell of a building using SIPs is also much faster then framing with dimensional lumber.

Typically, SIPs are made with ⅝ inch OSB and either expanded polystyrene (EPS) foam or polyurethane (PU) foam. The EPS foam is cut into dimensional sheets and the inside faces of the OSB sheets are glued to the EPS sheet. This produces a structurally strong and well insulated panel. PU SIPs are manufactured by placing two OSB sheets in a jig and injecting the PU foam therebetween. Once the PU foam has hardened the PU SIP is ready for shipment to the construction site. Generally, SIPs are fabricated at the factory with window and door opening precut. In addition some PU SIPs also have preinstalled electrical conduit therein. Most SIPs have channels precut in the foam for installation of electrical wiring and/or plumbing.

Problems exist, however, in that SIPs are large and heavy, and shipment to a job site and erection of the SIPs are expensive. The average construction framing carpenter may not have the skill set to install SIPs so that a factory crew usually will have to erect the SIPs at the job site. OSB and plywood prices have greatly increased due to greater demands created by extensive building and have caused SIP prices to increase accordingly. Also OSB and plywood are susceptible to termite and/or carpenter ant infestation, wood decay from excessive trapped moisture, mold and/or mildew.

SUMMARY

What is needed is a building panel that is both structural and insulated, light weight, easy to erect, low cost, strong, able to be fabricated and/or modified at the job site, resistant to termite and/or carpenter ant infestation, and not affected by excessive moisture, mold, mildew, and widely fluctuating building lumber prices.

According to specific example embodiments of this disclosure, a rigid foam core having a thickness from about 5.5 inches for expanded polystyrene (EPS) or from about 3.5 inches for polyurethane (PU) to a maximum thickness (e.g., depending on insulation value “R-factor” desired) as required may be sandwiched between hat channels and angles. The hat channels may be attached together at various points so that the rigid foam may be held in tight compression between these hat channels. The hat channels may be shaped into three dimensional structural members having at least six bends along a long axis of the hat channel. For example, a hat channel with six bends will have three first faces substantially parallel with each other, four second faces substantially parallel with each other, wherein the three first faces may be substantially perpendicular to the four second faces and the three first faces may be substantially parallel with a long face of the rigid foam core. It is contemplated and within the scope of this disclosure that the bends of the first and second faces of the hat channel may be at any angle and relationship that may form the hat channel into a structural member. A nailing strip may be attached to an outside face of each of the hat channels. The nailing strip may comprise wood, treated wood, composite wood/plastic, etc.

The rigid foam core may have a minimum density of about one pound per cubic foot and a maximum density dependent upon workability and insulation value “R-factor” desired. The hat channels may be, for example but not limited to, galvanized steel or coated metal from about 20 gauge to about 14 gauge, formed into structural members and arranged in a standard centerline spacing. The spacing and gauge may be determined by the structural load requirements of the construction application. Channel or chases may be formed in the rigid foam core for electrical wiring and/or plumbing at the time of fabrication and/or during installation at the construction site.

A bottom track may be attached to a foundation and/or bottom plate, e.g., treated dimensional wood, and a bottom edge of the insulated structural panels attached thereto. The bottom track may be, for example but not limited to, light gauge galvanized steel or coated metal from about 20 gauge to about 14 gauge. A top plate may be attached to the top edge of the insulated structural panels and may be 2× (e.g., 2×4, 2×6, 2×10, etc.) dimensional wood, treated or untreated, metal channel from about 20 gauge to about 14 gauge galvanized steel or coated metal, etc. The top and bottom tracks (e.g., top and bottom plates) may be fastened to the insulated structural panels with screws, rivets, metal nails and/or spot welds depending upon structural load factors and job site conditions. The ties between the hat channels and angles may be metal, e.g., screws, rivets, spot welded tie rods, etc., or for reduced thermal bridging they may be, nylon, carbon composite filaments, rods, etc.

A method of manufacturing the insulated structural panels comprising a combination of structural hat channels and rigid foam insulation, according to specific example embodiments of this disclosure, may comprise rigid foam cutting equipment, metal forming equipment and panel fabrication and attachment equipment. The panels may be manufactured in a factory using computer aided design and computer aided manufacturing (CAD/CAM) and/or the panels may be fabricated at the job site so as to utilized locally obtainable raw materials, e.g., flat metal and rigid foam. Fabrication at the job site may reduce shipping costs and increase flexibility in panel design lead time. In addition, larger panels may be readily fabricated at the job site because shipping of oversized loads is no longer required. The manufacturing equipment may be mounted on trucks and/or trailers or may be shippable and easily set up at or near the job site. Thus, construction of a large building or housing subdivision may have a insulated structural panel manufacturing facility that is close to the job site, resulting in lower delivery costs, shorter delivery times and easy customization and/or modification of the insulated structural panels. Also any panel shortages caused by field changes or manufacturing errors may be easily remedied by supplying replacement panels that may be easily fabricated as soon as they are needed at the job site.

According to specific example embodiments of this disclosure, the insulated structural panels may be easy adapted for use as walls, roof and/or floors of a residential or commercial building.

According to specific example embodiments of this disclosure, the hat channels may make substantially 100 percent contact with the rigid foam for increased lateral and axial load capabilities.

According to specific example embodiments of this disclosure, the insulated structural panels may be a very high strength to weight ratio and improved cost effectiveness for R-value obtained.

According to specific example embodiments of this disclosure, the insulated structural panels may have widened attachment points (e.g., three inches) at hat channel to top and bottom angles that may greatly improve lateral load capabilities.

According to specific example embodiments of this disclosure, the insulated structural panels may be used for 100 percent “green” building at reasonable cost.

According to specific example embodiments of this disclosure, the insulated structural panels may be configured as flat/straight walls with a known and provable strength capability.

According to specific example embodiments of this disclosure, the insulated structural panels may be manufactured with relatively inexpensive equipment.

According to specific example embodiments of this disclosure, the insulated structural panels may facilitate lower utility costs because of improved R-factor (insulation).

According to specific example embodiments of this disclosure, the insulated structural panels may be easy to install by basic unskilled labor. Two persons may install an 8 foot long by 8 foot high panel with relative ease.

According to specific example embodiments of this disclosure, the insulated structural panels may be limited in size only by shipping or jobsite limitations.

According to specific example embodiments of this disclosure, the insulated structural panels may be relatively easy to install electrical wiring and electrical boxes, plumbing, etc.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present disclosure thereof may be acquired by referring to the following description taken in conjunction with the accompanying drawings wherein:

FIG. 1 is a schematic drawing of an insulated structural panel, according to a specific example embodiment of this disclosure;

FIG. 2 is a schematic drawing of the insulated structural panel of FIG. 1 showing a base channel and a 2× dimensional lumber header, according to a specific example embodiment of this disclosure;

FIG. 3 is a schematic drawing of a portion of the insulated structural panel of FIG. 1 showing a more detailed view of the hat channel, angle and top plate attachment, according to a specific example embodiment of this disclosure;

FIG. 4 is a schematic drawing of a portion of the insulated structural panel of FIG. 1 showing a more detailed view of a bottom channel attached to the panel, according to a specific example embodiment of this disclosure;

FIG. 5 is a schematic drawing of a portion of the insulated structural panel of FIG. 1 showing a more detailed cutaway view of an electrical chase, according to a specific example embodiment of this disclosure;

FIG. 6 is a schematic drawing of a portion of the insulated structural panel of FIG. 1 showing the attachment of parallel hat channels in more detail, according to a specific example embodiment of this disclosure;

FIG. 7 is a schematic view of a portion of the hat channels without the rigid foam core, according to a specific example embodiment of this disclosure;

FIG. 8 is a schematic view of a hat channel end, according to a specific example embodiment of this disclosure;

FIG. 9 is a schematic cross sectional view of a hat channel, according to a specific example embodiment of this disclosure;

FIG. 10 is a schematic drawing of a top view of the insulated structural panel of FIG. 1, according to a specific example embodiment of this disclosure;

FIG. 11 is a schematic drawing of a typical foundation connection of the insulated structural panel of FIG. 1;

FIG. 12 is a schematic drawing of a roof truss connected to the insulated structural panel of FIG. 1;

FIG. 13 is a schematic drawing of the insulated structural panels of FIG. 1 connected together at a corner; and

FIG. 14 is a schematic drawing of door/window header and jamb details for the insulated structural panel of FIG. 1.

While the present disclosure is susceptible to various modifications and alternative forms, specific example embodiments thereof have been shown in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific example embodiments is not intended to limit the disclosure to the particular forms disclosed herein, but on the contrary, this disclosure is to cover all modifications and equivalents as defined by the appended claims.

DETAILED DESCRIPTION

Referring now to the drawings, the details of specific example embodiments are schematically illustrated. Like elements in the drawings will be represented by like numbers, and similar elements will be represented by like numbers with a different lower case letter suffix.

Referring to FIG. 1, depicted is a schematic drawing of an insulated structural panel, according to a specific example embodiment of this disclosure. The insulated structural panel, generally represented by the numeral 100, may comprise a rigid foam core 102, a plurality of hat channels 104, top L-channels 106, and bottom L-channels 108. The plurality of hat channels 104, top L-channels 106, and bottom L-channels 108 may be on either long side of the rigid foam core 102, e.g., the rigid foam core 102 is “sandwiched” therebetween. The rigid foam core 102 may be, for example but not limited to, expanded polystyrene (EPS), polyurethane (PU) and the like. The L-channels 106 and 108 may be fastened to the hat channels 104 by any appropriate means, e.g., sheet metal screws 110. At least one utility chase 112 may be placed in the rigid foam core 102 and may be substantially vertical and/or horizontal.

Referring to FIGS. 2, 3 and 4, depicted are schematic drawings of the insulated structural panel of FIG. 1 showing a base channel 220 and a 2× dimensional lumber header 222. The base channel 220 may be attached to the bottom L-channels 108 and the plurality of hat channels 104 by any appropriate means, e.g., sheet metal screws 110. The base channel 220 may also be attached to a building foundation 426 or floor (not shown). The base channel 220 may be securely attached to the foundation 426 or a floor (not shown) in a level and straight manner so that the insulated structural panel 100 may be even and straight when installed thereon. A header 222 may be attached to the top L-channels 106 by any appropriate means, e.g., sheet metal straps 224 and sheet metal screws 110.

Referring to FIG. 5, depicted s a schematic drawing of a portion of the insulated structural panel of FIG. 1 showing a more detailed cutaway view of the electrical chase 112, according to a specific example embodiment of this disclosure. Since the electrical chase 112 is exposed during construction, wiring and device electrical boxes may be easily installed in the rigid foam core 102.

Referring to FIG. 6, depicted is a schematic drawing of a portion of the insulated structural panel of FIG. 1 showing the attachment of parallel hat channels 104 in more detail, according to a specific example embodiment of this disclosure. The hat channels 104 may be attached together with ties 602, e.g., screws, tie rods, etc., or for reduced thermal bridging they may be, nylon, carbon composite filaments, rods, etc. so as to maintain compression of the rigid foam core 102. The rigid foam core 102 may additionally be glued or otherwise attached to the inside faces of the hat channels 104. Referring also to FIG. 10, depicted is a schematic drawing of a top view of the insulated structural panel of FIG. 1. There may be a plurality of ties 602 biasing together opposing hat channels 104, e.g., on opposite faces of the rigid foam core 102. The ties 602 in combination with the hat channels 104 and rigid foam core 102 may provide an I-beam type of structure.

Referring now to FIGS. 7, 8 and 9, depicted are schematic views of portions of the hat channels, according to a specific example embodiment of this disclosure. The hat channels 104 may be shaped into three dimensional structural members having at least six bends, generally represented by the numeral 704, along a long axis of the hat channel 104. For example, a hat channel 104 with six bends 704 will have three first faces 706 substantially parallel with each other, four second faces 708 substantially parallel with each other, wherein the three first faces 706 may be substantially perpendicular to the four second faces 708 and the three first faces 706 may be substantially parallel with a long face of the rigid foam core 102. It is contemplated and within the scope of this disclosure that the bends of the first and second faces 706 and 708 may be at any angle and relationship that may form the hat channel 104 into a structural member.

Referring to FIG. 11, depicted is the insulated structural panel 100 attached to a concrete foundation footer 426 a with a foundation tie strap 1120.

Referring to FIG. 12, depicted is a schematic drawing of a roof truss connected to the insulated structural panel of FIG. 1. The roof truss 1202 may be attached to the top plate 222 by any appropriate means, e.g., sheet metal straps and/or nails, etc.

Referring to FIG. 13, depicted is a schematic drawing of insulated structural panels 100 a and 100 b connected together at a corner by any appropriate means, e.g., sheet metal straps, sheet metal screws, etc. (not shown).

Referring to FIG. 14, depicted is a schematic drawing of door/window header and jamb details that may be incorporated into the insulated structural panels 100. A king hat channel 104 may be attached to upper and lower L-channels 106 a and 106 b, respectively. A short hat channel 104 a may be connected to the upper and lower L-channels 106 a and 106 b, respectively. For greater head loads, e.g., wider header spans, at least one additional horizontal hat channel 104 b may be included in the header on each side (face) of the foam core 102.

While embodiments of this disclosure have been depicted, described, and are defined by reference to example embodiments of the disclosure, such references do not imply a limitation on the disclosure, and no such limitation is to be inferred. The subject matter disclosed is capable of considerable modification, alteration, and equivalents in form and function, as will occur to those ordinarily skilled in the pertinent art and having the benefit of this disclosure. The depicted and described embodiments of this disclosure are examples only, and are not exhaustive of the scope of the disclosure. 

1. A insulated structural panel, comprising: a rigid foam core having first and second faces; a plurality of hat channels on the first and second faces of the rigid foam core; first L-channels on the first and second faces of the rigid foam core toward a first edge of the rigid foam core; second L-channels on the first and second faces of the rigid foam core toward a second edge of the rigid foam core wherein the second edge is opposite and parallel to the first edge; the first and second L-channels are substantially perpendicular to the plurality of hat channels and are attached thereto; opposing ones of the plurality of hat channels are attached together so as to be in compression with the first and second faces of the rigid foam core; wherein each of the plurality of hat channels are three dimensional structural members having at least six bends along a long axis thereof.
 2. The insulated structural panel according to claim 1, wherein each of the plurality of hat channels comprises at least three first faces and at least four second faces.
 3. The insulated structural panel according to claim 2, wherein the at least three first faces are substantially parallel with each other, the at least four second faces are substantially parallel with each other, and the at least three first faces are substantially perpendicular with the at least four second faces.
 4. The insulated structural panel according to claim 1, wherein the plurality of hat channels are embedded into surfaces of the first and second faces of the rigid foam core.
 5. The insulated structural panel according to claim 1, further comprising at least one utility chase in the rigid foam core.
 6. The insulated structural panel according to claim 1, wherein the first and second L-channels, and the plurality of hat channels are attached together with sheet metal screws.
 7. The insulated structural panel according to claim 1, wherein the first and second L-channels and the plurality of hat channels are attached together with rivets.
 8. The insulated structural panel according to claim 1, wherein the opposing ones of the plurality of hat channels are attached together with metal screws.
 9. The insulated structural panel according to claim 1, wherein the opposing ones of the plurality of hat channels are attached together with non-thermally conductive means.
 10. The insulated structural panel according to claim 1, further comprising gluing the plurality of hat channels to the rigid foam core.
 11. The insulated structural panel according to claim 1, wherein the plurality of hat channels are metal.
 12. The insulated structural panel according to claim 1, wherein the plurality of hat channels are steel.
 13. The insulated structural panel according to claim 12, wherein the plurality of hat channels are light gauge steel.
 14. The insulated structural panel according to claim 13, wherein the light gauge steel is from about 20 gauge to about 14 gauge.
 15. The insulated structural panel according to claim 13, wherein the light gauge steel is galvanized.
 16. The insulated structural panel according to claim 13, wherein the light gauge steel is coated to inhibit rust.
 17. The insulated structural panel according to claim 1, wherein the first and second L-channels are steel.
 18. The insulated structural panel according to claim 17, wherein the first and second L-channels are light gauge steel.
 19. The insulated structural panel according to claim 18, wherein the light gauge steel is from about 20 gauge to about 14 gauge.
 20. The insulated structural panel according to claim 18, wherein the light gauge steel is galvanized.
 21. The insulated structural panel according to claim 18, wherein the light gauge steel is coated to inhibit rust.
 22. The insulated structural panel according to claim 1, further comprising a nailing strip attached to an outside face of each of the plurality of hat channels.
 23. The insulated structural panel according to claim 22, wherein the nailing strip is wood.
 24. The insulated structural panel according to claim 22, wherein the nailing strip is treated wood.
 25. The insulated structural panel according to claim 22, wherein the nailing strip is wood.
 26. The insulated structural panel according to claim 1, wherein the rigid foam core comprises expanded polystyrene.
 27. The insulated structural panel according to claim 1, wherein the rigid foam core comprises polyurethane.
 28. A insulated structural panel, comprising: a rigid foam core having first and second faces; a plurality of hat channels on the first and second faces of the rigid foam core; top L-channels on the first and second faces of the rigid foam core toward a top edge of the rigid foam core; bottom L-channels on the first and second faces of the rigid foam core toward a bottom edge of the rigid foam core wherein the bottom edge is opposite and parallel to the top edge; the top and bottom L-channels are substantially perpendicular to the plurality of hat channels and are attached thereto; opposing ones of the plurality of hat channels are attached together so as to be in compression with the first and second faces of the rigid foam core; wherein each of the plurality of hat channels are three dimensional structural members having six bends along a long axis thereof, three first faces substantially parallel with each other, four second faces substantially parallel with each other, wherein the three first faces are substantially perpendicular to the four second faces.
 29. The insulated structural panel according to claim 28, wherein the bottom L-channels are adapted for connection to a bottom plate.
 30. The insulated structural panel according to claim 29, wherein the bottom plate is adapted for connection to a foundation.
 31. The insulated structural panel according to claim 28, wherein the top L-channels are adapted for connection to a top plate.
 32. The insulated structural panel according to claim 31, wherein the top plate is adapted for connection to a second floor.
 33. The insulated structural panel according to claim 31, wherein the top plate is adapted for connection to a roof support means.
 34. The insulated structural panel according to claim 1, further comprising a header of hat channels forming an opening in the rigid foam core for a window or door. 